Process for manufacturing silicon carbide valve disc for nuclear reactors

ABSTRACT

A main steam relief valve for use in a nuclear power plant. The valve disc includes a cylindrical first end of uniform external and internal circumference, a conical opposite end, an external surface, and an internal surface. The cylindrical first end preferably includes a plurality of groves on the external surface to prevent rotation of the disc. The conical portion is highly polished on the external surface to prevent the formation of cracks and is adapted to receive a push-rod on the internal surface and a valve seat on the external surface. The valve disc is constructed of approximately of 90% or greater silicon carbide.

This application is a division of U.S. patent application Ser. No. 09/666,580, filed Sep. 21, 2000 now U.S. Pat. No. 6,431,521.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to noncorrosive steam pressure safety release valves, and more particularly, to a valve disc for use in power generating nuclear fission reactor plants and associated equipment.

2. Description of the Prior Art

Steam pressure relief valves are critical devices in any type of high pressure, hot water, or steam producing units. In a nuclear power plant there are standards and demands that must be applied to the design and fabrication of such valves. The function of the steam pressure relief valve is shown conceptually in the illustration of FIG. 1. The principles of nuclear power generation are well established and understood. The nuclear reactor 10 is located in a containment building 11 and contains uranium or plutonium fuel elements in a core arrangement. Through neutron absorption and nuclear fission (chain reaction) of the uranium or plutonium, large amounts of energy are released in the form of heat which is utilized to generate electricity.

In a boiling water reactor, the chain reaction boils the moderator-water in the core. Steam is thus produced inside the reactor 10. Steam pipes 12 carry the steam from the reactor 10 to the turbines 13. In producing electricity, a nuclear plant's steam turbines and electric generators work like those in a fossil fuel plant. The steam produced by a reactor spins the blades of the plant's turbines 13, which drive the generators. Many plants have combination turbines and generators called turbogenerators.

After steam has passed through a plant's turbines 13, it is piped to a condenser 14. The condenser 14 changes the steam back into water 15. Water 15 is then returned to reactor 10 by pump 16. There are several conditions that may occur in the nuclear plant which require a relief of steam pressure from the system. For this reason, a steam relief safety valve 17 is used in the steam pipe system. The purpose of the valve 17 generally is to relieve steam pressure in excess of 1150 pounds per square inch (“psi”) to prevent overpressurization of the nuclear reactor and subsequent damage and potential shut down. This overpressure could be caused by several events such as a main electrical breaker closure which eliminates the resistance to the power turbines, or any misadventure that might cause overpressure with subsequent excessive revolutions per minute (“rpm”) of the turbines. To prevent excessive rpm to the turbines, the steam power to them is shut down with the pressure then traveling back to the reactor. The valve 17 is designed to then exhaust the excess steam above 1150 psi.

The present invention relates to two-stage safety relief valves as part of the nuclear pressure relief system in boiling water reactors to provide automatic depressurization, if needed, for breaks in the nuclear system so that the low pressure coolant injection and the core spray systems can operate to protect the fuel barrier. This two-stage valve is referred to as a main steam relief valve which is installed in the main steam lines. The main steam relief valves are distributed among the four main steam lines so that an accident cannot completely disable a safety, relief, or automatic depressurization function. Of the nuclear plants that use this valve, each reactor (typically 2-3 per plant) has approximately thirteen of these valves along the main steam line.

The typical main steam relief valve contains a disc which engages a seat when the valve is in the closed position. The disc and seat are presently made of stellite, a cobalt-based metal containing chromium and carbon. The main problem for the nuclear energy plant is risk of overpressure to the nuclear reactor because of the occasional failure of the main steam relief valve to relieve at the designated pressure. This condition is due to corrosion bonding of the stellite disc to the stellite seat as a result of exposure to radiation, heat, moisture, and oxygen from the steam. Plating the disc with platinum has improved the function of the disc but has not cured the problem of corrosion and bonding of the valve to the seat.

Valve discs made of ceramics might be resistant to this corrosive and bonding effect in nuclear plants. However, oxide-based ceramics would not be useful because the presence of oxide causes the ceramic to easily corrode in the presence of oxygen, high temperatures, alkalis, and acids. On the other hand, silicon carbide ceramic is known to be highly resistant to corrosion under extreme conditions. However, it is a complicated process to sinter silicon carbide because it has to be sintered at high temperatures in an inert atmosphere. The stellite valve disc in present use in nuclear reactors has a complex shape which would make construction of a similar valve out of silicon carbide highly impractical. The stellite disc has a conical shape on one end and a cylindrical shape on the opposite end. The cylindrical portion has three different external diameters and two different internal diameters which would make the construction of this valve from silicon carbide unfeasible. To my knowledge, no alternative valve disc composed of silicon carbide has ever been made available for a nuclear power plant heretofore.

The present invention has solved these and other shortcomings by providing a silicon carbide valve disc for use in a main steam relief valve. The cylindrical portion of this disc has a uniform external diameter and a uniform internal diameter and is feasible to construct entirely from silicon carbide or similar carbide ceramics.

SUMMARY OF THE INVENTION

One aspect of the present invention relates to a main steam relief valve for use in a boiling water reactor nuclear power plant. In particular, the valve of the present invention is a valve for regulating steam pressure in a nuclear power plant, comprising: a hollow disc including a cylindrical first end having a uniform external and internal circumference, a conical opposite end, an external surface, and an internal surface, said conical portion adapted to receive a push-rod on the internal surface and a valve seat on the external surface, wherein said disc comprises a ceramic carbide. The valve disc has a cylindrical first end of uniform external and internal circumference, a conical opposite end, an external surface, and an internal surface. The cylindrical first end has a plurality of groves on the external surface to prevent rotation of the disc and to allow steam to exhaust. The conical portion is highly polished on the external surface to prevent the formation of cracks. The conical portion is adapted to receive a push-rod or a steel plate and push-rod on the internal surface, and a valve seat on the: external surface. The valve disc is constructed entirely of 90% or greater oxide-free silicon carbide, boron carbide, titanium diboride, or boron nitride. The disc is highly resistant to destruction by physical impact by virtue of the thickness of its walls and its conical portion. In a preferred embodiment, the disc is constructed from superfine powders of silicon carbide, hot pressed to rough shape, premachined, sintered at high temperature, diamond wheel ground, and polished.

An advantage of the present invention is to provide a valve disc for a nuclear power plant that is resistant to corrosion during operation of the nuclear power plant.

Another advantage of the present invention is to provide a valve disc for a nuclear power plant which will not bond to its valve seat during operation of the nuclear power plant.

Another advantage of the present invention is to provide a valve disc for a nuclear power plant that is resistant to destruction by physical impact.

Yet another advantage of the present invention is to provide a valve disc for a nuclear power plant that is constructed of silicon carbide, boron carbide, titanium diboride, or boron nitride with purity of 90% or greater.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic view of a typical boiling water reactor in a nuclear power plant, known in the art showing the placement of the main steam release valve.

FIG. 2 is a perspective view of the silicon carbide valve disc of the present invention.

FIG. 3 shows a diagrammatic view of the disc in a valve assembly, with the disc in place on a valve seat.

FIG. 4 is a horizontal cross-sectional view of the disc of FIG. 2.

FIG. 5 is a vertical cross-sectional view of the disc of FIG. 2.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 is a diagrammatic view of a typical boiling water reactor showing the placement of the main steam release valve. FIG. 2 shows a perspective view of an exemplary embodiment of a valve disc in accordance with the present invention. The valve disc 20 has a cylindrical first end 21 and an opposite conical end 22. The disc is hollow so that it will have an exterior surface 23 and an interior surface 24 (see FIGS. 4 and 5). The tip 25 of conical end 22 is a nipple or papilla-like structure to facilitate seating of the disc 20 within the valve. Surface 23 of cylindrical end 21 has a uniform circumference. Conical end 22 forms an approximate 71° flair with the external surface 23 of cylindrical end 21, ranging between about 60°-80°. Cylindrical end 21 has a plurality of grooves 26 in exterior surface 23, which accommodate projections within the valve to keep the disc aligned, prevent the disc from rotating about its longitudinal (vertical) axis 36 (see FIG. 5) when in use, and allow steam to exhaust to relieve pressure.

FIG. 3 shows disc 20 in a main steam relief valve 30 in place against valve seat 31 on conical exterior surface 22, thereby closing the valve. The arrows indicate the direction of steam flow if the valve were open. Plunger or push-rod 33 fits within the hollow portion 27 (see FIG. 5) so that it can push disc 20 onto valve seat 31 with whatever force is required. When steam pressure exceeds a certain value, thereby exceeding the force of the plunger, it pushes the disc 20 away from valve seat 31, opening the valve and allowing steam to escape.

FIG. 4 shows a horizontal cross-sectional view of the disc 20 of FIG. 2. The walls of the cylindrical first end 21 are defined by the internal surface 24 and external surface 23. The maximum external diameter of cylindrical first end 21, defined by the circumference of the external surface 23, is approximately 1.752 inches, ranging between 1.0 and 2.5 inches. This diameter and circumference are uniform along the length of cylindrical end 21. The internal diameter of cylindrical first end 21 is approximately 1.12 inches, ranging between 0.8 to 1.6 inches. Internal surface 24 of cylindrical end 21 has a uniform circumference along the length of cylindrical end 21. Likewise, the corresponding internal diameter is uniform. Maximum wall thickness of the cylindrical first end 21 is approximately 0.316 inches, ranging between 0.16 and 0.8 inches. The minimum wall thickness, measured from the center of groove 26, is approximately 0.16 inches, ranging from 0.08 to 0.4 inches.

FIG. 5 shows a vertical cross-sectional view of the disc 20 of FIG. 2. Cylindrical first end 21 has a base 28 and opposite conical end has a tip 25. The internal or hollow portion 27 of the disc is contained within the cylindrical end 21. Conical end 22 is solid so that a flat dome or roof 29 is formed in the internal hollow portion 27. A soft circular steel plate 35 can be reversibly inserted into hollow portion 27 and placed adjacent to inner surface 24 at dome 29 in between said dome 29 and said push-rod 33 to spread impact load uniformly and to reduce fracture stress from push-rod 33. The length of the longitudinal axis 36 of disc 20, extending from base 28 to tip 25 is approximately 2.5 inches, ranging between 1.8 to 3.3 inches. The thickness of the opposite conical end 22 from the external tip 25 to the internal flat dome 29 is approximately 1.28 inches, ranging between 1.0 and 2.0 inches. Internal dome 29 is adapted to accept push-rod 33 (see FIG. 3) or flat plate 35 interposed between push-rod 33 and internal dome 29. The length of cylindrical first end 21, denoted by the letters A and B, is approximately 1.39 inches, ranging between 0.6 and 1.8 inches. The angular length of opposite conical end 22, denoted by the letters B and C, is approximately 1.28 inches, ranging from 0.55 to 1.73 inches. The height of tip 25 is approximately 0.09 inches, ranging from 0 to 0.2 inches, and the diameter of the tip is approximately 0.283 inches, ranging from 0.12 to 0.35 inches. The diameter of circular steel plate 35 is approximately 1.0 inches, ranging between 0.7 and 2.3 inches. The thickness of steel plate 35 is 0.2 inches, ranging between 0.1 and 0.3 inches. The angle D formed between cylindrical first end 21 and opposite conical end 22 is about 71°, ranging between 60°-80°.

The valve disc of the present invention is composed of and fashioned from ceramic carbide, preferably from 98.0% (wt %) silicon carbide (SiC), or boron carbide, titanium diboride, or boron nitride, which contain trace amounts of other metals, and which are available commercially, for example, from The Carborundum Corporation (Niagara Falls, N.Y.) or AC Cerama (Sweden). The sintering process results in a single-phase, fine-grain silicon carbide product that's very pure and uniform, with virtually no porosity. The material is extremely durable, whether submerged in corrosive environments, subjected to extreme wear and abrasive conditions, or exposed to temperatures in excess of 1400° C. This silicon carbide, as well as the other carbides disclosed, are among the hardest, yet strongest, high performance materials available, second only to diamonds (2800 kg/mm2 at room temperature), and have excellent resistance to creep and stress rupture at temperatures up to 1,650° C. They resists corrosion, oxidation and erosion. The high density, low porosity and chemical inertness of these carbides permit them to function in environments of hot gases and liquids, in oxidizing and corrosive atmospheres, in strong acids and bases, even at extremely high temperatures, and in exposure to high radioactivity.

Although the disc is fashioned preferably from 98% (wt %) silicon carbide, lesser purity may be used ranging from 90% and higher. The disc is fashioned from superfine silicon carbide powders, hot pressed to rough shape, premachined, and sintered at high temperature under conditions well-known in the art. The disc is then diamond-wheel ground in successively fine (diamond gait size) wheels and final ground by polishing (successively fine grit and polishing papers and cutting fluids). The disc is then exposed to another heat treatment, between 1,500 and 3,000° F., preferably at 2,500° F., for 6 to 12 hours, preferably eight hours, followed by polishing with clear oil, such as, for example, standard commercial baby oil, and with paper tissue, such as, for example, bathroom tissue (toilet paper) or facial tissue.

The foregoing description has been limited to specific embodiments of this invention. It will be apparent, however, that variations and modifications may be made by those skilled in the art to the disclosed embodiments of the invention, with the attainment of some or all of its advantages and without departing from the spirit and scope of the present invention. For example, the longitudinal grooves in the cylindrical end may have various shapes to accommodate various interlocking mechanisms, or the cylindrical end may have no grooves. The amount and quantity of trace metals in the silicon carbide or other ceramic carbides may be varied. The internal dome may assume various shapes and forms to accommodate the head of a plunger or push-rod. The external tip on the conical end may take various shapes and sizes or be removed. The conical end may have a plurality of angles relative to the cylindrical end or be flat.

It will be understood that various changes in the details, materials, and arrangements of the parts which have been described and illustrated above in order to explain the nature of this invention may be made by those skilled in the art without departing from the principle and scope of the invention as recited in the following claims. 

I claim:
 1. A process for manufacturing a ceramic disc, comprising: a) hot pressing, superfine ceramic carbide powder to a rough shape of a disc; b) premachining said disc; c) sintering said disc at high temperature; d) diamond-wheel grinding said disc; e) polishing said disc after said diamond-wheel grinding; f) heating said disc at high temperature; and g) polishing said disc with clear oil and paper tissue.
 2. The process according to claim 1 wherein said ceramic carbide powder is selected from the group consisting of 90% or greater silicon carbide, boron carbide, titanium diboride, and boron nitride.
 3. The process according to claim 2 wherein said ceramic carbide powder is silicon carbide.
 4. The process according to claim 3 wherein said heating is between about 1,500° F. to 3,000° F. for between about 6 to 10 hours.
 5. The process according to claim 4 wherein said heating is at approximately 2,500° F. and for approximately 8 hours.
 6. The process according to claim 1 wherein said diamond-wheel grinding said disc is performed with fine, diamond gait size wheels.
 7. The process according to claim 1 wherein said polishing said disc after said diamond wheel grinding is performed with successively fine grit, polishing papers, and cutting fluids.
 8. The process of claim 1 wherein said clear oil is baby oil and said tissue is bathroom tissue.
 9. A process for manufacturing a ceramic disc for regulation of steam pressure in a nuclear power plant, comprising: a) obtaining super fine ceramic carbide powder selected from the group consisting of 90% or greater silicon carbide, boron carbide, titanium diboride, and boron nitride; b) hot pressing said ceramic carbide powders to a rough shape of a disc; c) premachining said disc; d) sintering said disc at high temperature; e) diamond-wheel grinding said disc with fine, diamond gait size wheels; f) polishing said disc with successively fine grit, polishing papers, and cutting fluids; g) heating said disc at high temperature; and h) polishing said disc with clear oil and paper tissue.
 10. The process according to claim 9 wherein said ceramic carbide powder is silicon carbide.
 11. The process according to claim 10 wherein said heating is between about 1,500° F. to 3,000° F. for between about 6 to 10 hours.
 12. The process according to claim 11 wherein said heating is at approximately 2,500° F. and for approximately 8 hours.
 13. The process according to claim 9 wherein said clear oil is baby oil and said tissue is bathroom tissue. 